2003 DAEWOO MATIZ check engine

CLUTCH 5C–5
DAEWOO M-150 BL2
CLUTCH PEDAL OPERATION
D103C301
Clutch pedal free travel
It is designed that there is no clutch pedal free travel.
Clutch pedal travel (A)

Pedal Travel

100–110 mm (3.9–4.3 in.)
Clearance between pedal and floor just
before clutch connection (B)
After starting the engine, check if the clearance between
pedal and floor is within specified range in condition of
idling, lifting, parking brake and drawing out clutch ped-
al.

Clearance Between Pedal and Floor
just Before Clutch Connection
30–40 mm
(1.2–1.6 in.)
Caution: During inspection, take care on sudden
departure.
CLUTCH CABLE ADJUSTMENT
D103C302
If clutch connection / disconnection is operated un-
smoothly, adjust the clutch cable by adjusting clutch
cable adjust nut.

POWER STEERING GEAR 6C–3
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER RACK AND PINION STERING GEAR
ConditionProbable CauseCorrection
Hissing Noise
Loose steering coupling joints.
Tighten the steering coupling
joints.

Improperly contacted the power
steering hose with other
components.
Fit the power steerng hose into
the hose clips correctly.
Rattling Noise in Steering Gear
Improperly contacted the power
steering line with the body.
Fix the steering line correctly.

Insufficient lubricant.
Lubricate the steering gear.

Loose steering gear mounting.
Tighten the steering gear
mounting bracket bolts.

Improperly installed tie rod ends.
Tighten the tie rod joints and
replace the tie rod end as needed.
Poor Return of Steering Wheel
to Center
Improperly contacted the steering
wheel with the turn signal housing.
Adjust the turn signal housing.

Improper binding or looseness of
steering coupling.
Replace the intermediate shaft.

Stuck and improperly aligned
power steering pump flow control
valve.
Replace the power steering pump.

Improper binding or looseness of
tie rods and ball joints.
Tighten the tie rods and the ball
joints. Replace the tie rods and
the ball joints as needed.

Poor adjustments of the steering
gear.
Perform a straight-ahead check.
Momentary Increase in Effect
When Turning the Wheel
Internal leaks of the power
steering pump.
Replace the power steering pump.
Quickly
The damage or restricted flow of
the hoses.
Replace the power steering hoses
and pipes.

Insufficient power steering fluid.
Fill the power steering fluid
reservoir.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.
Steering Surges or Jerks When
Turning with Engine Running
Insufficient pressure of the power
steering pump.
Replace the power steering pump.

Stuck and improperly operated
power steering pump flow control
valve.
Replace the power steering pump.

The slippage of the pump drive
belt.
Tighten the pump drive belt.

Contaminated air in the power
steering system.
Bleed the power steering system.

7A–6 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
HEATER SYSTEM
INSUFFICIENT HEATING OR DEFROSTING
Caution: The cooling system is pressurized when hot. Injury can result from removing the surge tank cap
before the engine is sufficiently cool.
Step Action Value(s) Yes No

1

Verify the customer’s complaint.
Are the customer’s concerns verified?
–
Go to Step 2

System OK
2 Check the coolant level.
Is the coolant level correct? – Go to Step 4 Go to Step 3
3

Add coolant as needed.
Is the repair complete?
–

System OK

Go to Step 4
4

Check the timing belt for tension or damage.
Is the timing belt OK?
–

Go to Step 6

Go to Step 5

5

Correct any problem with the drive belts.
Is the repair complete?
–
System OK

Go to Step 6

6

Check the coolant hoses for leaks or kinks.
Are the coolant hoses OK?
–
Go to Step 8

Go to Step 7
7 Repair any problem with the coolant hoses.
Is the repair complete? –
System OK

Go to Step 8

8



Check the surge tank cap. Refer to Section 1D,
Engine Cooling.
Is the surge tank cap OK?


–


Go to Step 10


Go to Step 9

9


Repair or replace the surge tank cap as needed.
Is the repair complete?
–

System OK

Go to Step 10






10






1. Set the A/C switch OFF on vehicles equipped
with air conditioning.
2. Set the blower motor switch on 4.
3. Set the heater control to full hot.
4. Turn the ignition ON.
5. Check for airflow from the heater outlet.
Is there heavy airflow from the heater outlet?





–





Go to Step 11





Go to Step 25



11



Check for a change in the airflow at various blower
speeds.
Does the blower speed increase as the switch is
turned from 1 to 4?


–


Go to Step 12


Go to ‘‘Blower
Electrical’’








12








1. Set the A/C switch to OFF, on vehicles equipped
with air conditioning.
2. Set the temperature lever to full hot.
3. Set the blower motor switch on 4.
4. With the engine sufficiently cool, remove the
surge tank cap.
5. Start the vehicle and idle the engine.
6. Watch for the flow of the coolant.
Is the coolant flow visible?







–







Go to Step 14







Go to Step 13

HEATING AND VENTILATION SYSTEM 7A–7
DAEWOO M-150 BL2
Insufficient Heating or Defrosting (Cont’d)
Step Action Value(s) Yes No





13





1. Check for a

Restriction in the cooling system.

Failed water pump impeller.

Faulty thermostat.
2. Make repairs to the cooling system, as needed.
Are the repairs complete?




–




System OK





–






14






1. Check the vehicle for cold air leaks at the

Dash.

Heater cases.

Vents.
2. Check under the seat for obstructions.
3. Repair any leaks or obstructions.
Are the repairs complete?





–





System OK






–






15






1. Turn the ignition OFF.
2. Turn the temperature control knob to full cold,
then rapidly to full hot.
3. Listen for the sound of the temperature door slam
just before reaching the end of the travel range of
the control knob.
Did the door slam?





–





Go to Step 17





Go to Step 16







16







1. Check the temperature door

Travel.

Cables.

Linkage.
2. Verify the accuracy of the temperature controls at
full hot.
3. Verify the accuracy of the temperature controls at
full cold.
Is the repair complete?






–






System OK







–





17





1. Set the temperature door to full hot.
2. Start the vehicle.
3. Check the temperature of the heater inlet hose
and the heater outlet hose by feel.
Is the heater inlet hose hot and the heater outlet
hose warm?




–




Go to Step 18




Go to Step 21


18



Check the thermostat. Refer to Section 1D, Engine
Cooling.
Is the thermostat installed and seated properly?


–


Go to Step 19


Go to Step 20

19


Replace the thermostat. Refer to Section 1D, Engine
Cooling.
Is the repair complete?
–

System OK

–

20

Reinstall the thermostat.
Is the repair complete?
–

System OK

–

21


Inspect the heater hoses for proper installation.
Are heater hoses reversed?
–

Go to Step 22

Go to Step 23

22

Reinstall the heater hoses properly.
Is the repair complete?
–
System OK

–

7A–8 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
Insufficient Heating or Defrosting (Cont’d)
Step Action Value(s) Yes No







23







1. Back flush the heater core.
2. Drain the cooling system.
3. Replace the coolant.
4. Warm the engine to an average operating
temperature.
5. Feel the heater inlet hose and the heater outlet
hose.
Is the heater inlet hose hot and the heater outlet
hose warm?






–






System OK






Go to Step 24
24

Replace the heater core.
Is the repair complete?

–

System OK

–




25




Recheck the system using the “Control
Settings/Correct Results” tests. Refer to ‘‘Improper
Air Delivery or No Mode Shift” in this section.
Is the repair complete?




–



System OK



Go to Step 26



26



Check for airflow from the defroster or the vent
outlets.
Is there high airflow from the defroster or the vent
outlets?


–


Go to Step 27


Go to Step 28

27



Adjust the heater door at the floor and the vent door
to get the proper airflow.
Is the repair complete?

–


System OK


–

28

Switch the mode knob to defrost.
Is the defroster airflow OK?
–

Go to Step 29

Go to Step 30




29




1. Remove the heater outlet and check for
obstructions.
2. Remove any obstructions in the heater outlet.
Is the repair complete?



–



System OK




–

30


Check for airflow change at various blower speeds.
Does the blower speed increase as the control is
turned from 1 to 4?
–

Go to Step 31

Go to ‘‘Blower
Electrical’’


31



Check for obstructions in the system at the blower
inlet.
Are there any obstructions?


–


Go to Step 32


Go to Step 33



32



Remove the obstructions in the system at the blower
inlet.
Is the repair complete?


–


System OK



–




33




1. Set the blower on 4.
2. Rotate the temperature control from full hot to full
cold.
3. Listen for an airflow change.
Does the airflow change?



–



Go to Step 34



Go to Step 35

HEATING AND VENTILATION SYSTEM 7A–11
DAEWOO M-150 BL2
IMPROPER AIR DELIVERY OR NO MODE SHIFT
This procedure provides a test of all functions of the heater/defroster unit.
1. Warm up the vehicle.
2. Keep the engine running.
3. Perform the tests outlined in the table below and look for the results indicated.
CONTROL SETTINGS CORRECT RESULTS



MODE
KNOB



TEMP.
CONTROL



BLOWER
MOTOR
SWITCH


BLOWER
SPEED



POWER
VENT
OUTLET


FLOOR
OUTLET



DEFROST
OUTLET



SIDE
WINDOW
OUTLET
Vent Cold Off Off No
Airflow No
Airflow No
Airflow No
Airflow



Vent

Cold

4

High

Ambient
Airflow
No
Airflow
No
Airflow
No
Airflow



Floor

Cold to Hot

4

High

No
Airflow
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow

Minimum
Cold to Hot
Airflow




Defroster


Cold to Hot


4


High



No
Airflow



Minimum
Cold to Hot
Airflow



Cold to Hot
Airflow



Minimum
Cold to Hot
Airflow
If any of these settings does not produce the correct results, perform the following diagnostic procedure.

Step

Action

Value(s)

Yes

No
1

Verify the customer’s complaint.
Are the customer’s concerns verified?

–

Go to Step 2

System OK




2





Examine the affected door in the unit for proper
cable attachment.

Check the cable connection to the door.

Check that the cable sheath is properly re-
tained.
Is the cable connected properly?




–




Go to Step 4




Go to Step 3
3

Repair as necessary.
Is the repair complete?
–

System OK

–





4





1. Disconnect the cable at the door.
2. Check the range of the door travel and the effort
required to move it.
Does the door move freely through its entire range
of travel so that it can close at both ends of the
range?




–




Go to Step 5




Go to Step 3

5


Check the travel of the Bowden cable by turning the
control knob.
Is the cable travel OK?
–

Go to Step 6

Go to Step 7



6




1. Reinstall the cable.
2. Recheck the system using the “Control
Settings/Correct Results” tests in this procedure.
Does the system perform properly?




–



System OK



Go to Step 9



7



1. Check the cable attachment at the control.
2. Check for a broken control.
Is there a problem with the cable attachment or the
control?


–


Go to Step 8


Go to Step 9

7A–14 HEATING AND VENTILATION SYSTEM
DAEWOO M-150 BL2
Too Much Heat (Cont’d)
Step Action Value(s) Yes No




14




1. Check the temperature door travel, the cables,
and the linkage.
2. Verify that the temperature door goes to full cold.
3. Check the temperature door for full hot.
Is the temperature door travel correct?



–



System OK




–




15




1. Check for hot air leaks from the engine
compartment to the blower inlet.
2. Repair as needed.
Is the repair complete?



–



System OK




–

MANUAL CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7B–5
DAEWOO M-150 BL2
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
TESTING THE REFRIGERANT
SYSTEM
If you suspect a problem in the refrigerant system,
check for the following conditions:
1. Check the outer surfaces of the radiator and the con-
denser cores to be sure that the airflow is not blocked
by dirt, leaves, or other foreign material. Check be-
tween the condenser and the radiator, as well as all
outer surfaces.
2. Check for restrictions or kinks in the condenser core,
the hoses, and the tubes.
3. Check the operation of the blower fan.
4. Check all the air ducts for leaks or restrictions. A low
airflow rate may indicate a restricted evaporator core.
5. Check for slippage of the compressor clutch.
6. Check the drive belt tension.
INSUFFICIENT COOLING “QUICK
CHECK” PROCEDURE
Perform the following “hand-feel” procedure to get a
quick idea of whether the air conditioning (A/C) system
has the proper charge of Refrigerant-134a.
1. Warm up the engine. Run the engine at idle.
2. Open the hood and all the doors.
3. Turn the A/C switch ON.
4. Set the temperature control to the full cold position.
5. Set the blower speed switch on 4.
6.“Hand-feel” the temperature of the evaporator outlet
pipe. The pipe should be cold.
7. Check for other problems. Refer to “Testing the Re-
frigerant System” in this section.
8. Leak check the system. Refer to “Leak Testing the
Refrigerant System” in this section. If you find a leak,
discharge the system and repair the leak as required.
After completing the repair, evacuate and charge the
system.
9. If there is no leak, refer to “Insufficient Cooling Diag-
nosis” in this section.